Buehler 11-2180 User manual

Brand: Buehler

Model: 11-2180

Type: User manual

This manual is also suitable for

IsoMet 1000

IsoMet

1000 Precision Saw

MA112180_33 6/27/2005

Declaration of Conformity

Manufacturer:

BUEHLER, Ltd.

Of:

41 Waukegan Road

Lake Bluff, Illinois 60044

IsoMet

1000 Precision Saw

Declares the following product:

To be in accordance with EC Directive(s);

Safety of Machinery: EMC Directive:

89/392/EEC and 91/368/EEC and 93/44/EEC

according to the following standards:

89/336/EEC and 92/231/EEC according to the

following standards:

EN 292 PART 1 1991

EN 292 PART 2 1991

EN 60204 PART 1 1993

EN 50081-2: 1998

Position: Engineering Manager

Name: Boyd Schindler

Signature:

Date: 6/27/2005

THIS MANUAL IS A CUSTOM GENERATED DOCUMENT. IT INCLUDES ALL

REVISIONS RELATIVE TO THIS SPECIFIC BUEHLER ITEM AS OF THE DATE

SHOWN BELOW.

The items covered in this communication including all attachments may be subject to the export laws of the United States

of America, including without limitation the Export Administration Regulations and the Office of Foreign Asset Control

Regulations. The export, re-export or diversion of these items in contravention of these or other applicable regulations is

strictly prohibited.

This information contained in this communication is intended only for the use of the individual or entity to which it is

addressed and may contain information that is privileged, confidential and exempt from disclosure under applicable law.

MA112180_33 6/27/2005

OPERATION AND MAINTENANCE

INSTRUCTIONS

BUEHLER

IsoMet

1000 Precision Saw

MA112180_33 6/27/2005

Table of Contents

IsoMet

1000 Precision Saw ............................................................................................................5

Warranty ...........................................................................................................................................5

Unpacking.........................................................................................................................................5

Safety Information.............................................................................................................................7

Machine Use and Care ............................................................................................................. 7

Installation.........................................................................................................................................8

Electrical Installation ................................................................................................................. 8

Activating the IsoMet

1000 Precision Saw ....................................................................... 9

Blade Installation....................................................................................................................... 9

Gang Sawing .................................................................................................................... 10

Flanges............................................................................................................................. 10

Blade Dressing ................................................................................................................. 10

Lubrication ........................................................................................................................ 11

Operation ........................................................................................................................................12

IsoMet

1000 Front Control Panel .......................................................................................... 13

Sample Arm ............................................................................................................................ 14

Loading the Saw ..................................................................................................................... 15

End of Cut Adjustment ............................................................................................................ 16

Cutting a Sample..................................................................................................................... 16

Maintenance ...................................................................................................................................18

Trouble Shooting Chart........................................................................................................... 18

IsoMet

1000 Accessories..............................................................................................................19

Chucks .................................................................................................................................... 19

Flanges ................................................................................................................................... 19

Other ....................................................................................................................................... 19

Wafering Blades...................................................................................................................... 20

MA112180_33 6/27/2005

IsoMet

1000 Precision Saw

The IsoMet

1000 Precision Saw offers increased speed, load, and blade size that enables a

wide variety of specimen samples to be cut quickly and with low deformation.

The IsoMet

1000 cutting compartment is fully enclosed and can be removed and replaced with

the accessory Table Saw Attachment for sectioning larger samples. The coolant tray can be

easily removed from the front of the machine for fast cleaning and for easy retrieval of cut

samples.

With a 7-inch diamond blade capacity and a wide selection of accessories, the IsoMet

1000

Precision Saw offers increased versatility and power for sectioning today’s advance materials.

Warranty

This unit is guaranteed against defective material and workmanship for a period of two (2) years /

2000 hours from the date of receipt by the customer. The warranty is void if inspection shows

evidence of abuse, misuse, unsafe use, or unauthorized repair. This warranty covers all Buehler

costs associated with the replacement of defective materials (e.g., parts, labor, and travel).

If for any reason this unit must be returned to Buehler Ltd. for warranty service, please apply for

prior authorization with shipping instructions. Please include the following information:

• Customer Purchase Order Number

• Buehler Invoice Number and Date

• Serial Number

• Reason for return

Unpacking

The IsoMet

1000 Precision Saw has been carefully packaged to protect it during transit from the

factory to your location. Carefully unpack and check the contents. If any components are

missing or damaged, save the packing list and materials and advise the carrier and Buehler, Ltd.

of the discrepancy.

Carefully unpack and check that the following items have been received:

• 11-1184 Bar and Tube Stock Chuck ● Hex Wrench ⅛ inch

• 11-1185 Irregular Specimen Chuck ● Hex Wrench

⁄

inch

• 11-1186 Wafering Chuck ● Hex Wrench

⁄

inch

• 11-1187 Small Single Saddle Chuck ● Hex Wrench

⁄

inch

• Pint IsoCut

Fluid ● Open End Hex ½ - ⅝ inch

• Series 15LC 6-inch Diamond Wafering Blade

• 2 3-inch Flanges

WARNING! Equipment Damage. The IsoMet

1000 Precision Saw weighs 75 lbs

(34 kg) and two persons are required to safely lift the unit from the shipping

carton.

MA112180_33 6/27/2005

The IsoMet

1000 Precision Saw is bolted to a wood base for protection during shipping. Open

areas are provided at the corners of the base for ease of lifting. Lift IsoMet

1000 Precision Saw

out of the carton and position it on a table so it overhangs on the edge. Remove the bolts

securing the IsoMet

1000 Precision Saw to the wood base.

Note: Do not remove the four bolts securing the motor to the IsoMet

1000 housing

(see Figure 1).

Securing Bolt (2)

Securing Bolt (1)

4 Bolts securing motor to

IsoMet

1000 housing.

Figure 1 IsoMet

1000 Wood Base

MA112180_33 6/27/2005

Safety Information

The IsoMet

1000 Precision Saw is designed to section metallurgical and petrographic materials

with recommended cutting wheels.

For safe installation and operation of this equipment, carefully read and understand the contents

of this manual. Improper operation, handling, or maintenance can result in equipment damage

and personal injury.

The IsoMet

1000 Precision Saw is designed for use in dry, indoor laboratory and workshop

environments away from strong electromagnetic fields and with normal temperature ranges

(41° F to 104° F / 5° C to 40° C) and non-condensing humidity ranges (30-90%).

Machine Use and Care

Dress properly. Do not wear loose clothing or jewelry and contain long hair. They can

be caught in moving parts and can result in severe personal injury. Protective equipment

should be worn to handle samples, which may be sharp or hot.

Do not operate machine in explosive atmospheres, such as in the presence of

flammable liquids, gases, or dust. Sparks may ignite the dust or fumes.

Always use safety glasses. Flying debris and liquids can cause severe eye injury.

Maintain the IsoMet

1000 Precision Saw with care. Properly maintained machines

are less likely to bind and are easier to control. Any alteration or modification is a misuse

and may result in a dangerous situation.

Maintain machine guards and interlocks. Do not attempt to enter the cutting bay when

the IsoMet

1000 Precision Saw is in use.

Only qualified repair personnel must perform machine service. Service or

maintenance performed by unqualified personnel could result in a risk of injury.

Replace damaged or defective parts immediately and use only identical

replacement parts. Use of unauthorized parts or failure to follow maintenance

instructions may create a risk of electrical shock or injury.

Check for misalignment or binding of moving parts, breakage of parts, and any

other condition that may affect the machine operation. If damaged, have the

machine serviced before using. Poorly maintained machines cause many accidents.

Do not abuse the power cord. Never use the cord to cart the machine or pull the

plug from an outlet. Keep the cord away from heat, oil, sharp edges, or moving

parts. Replace damage cords immediately. Damage cords increase the risk of

electrical shock.

Use of extension cords is not recommended for Buehler machines and equipment.

Machine coolant can present a biological hazard if not maintained correctly.

Change the coolant regularly in accordance with local regulations and safety practices.

• Coolant must be suitable for grinding cut-off use and protect against electrolytic

action between sample material and machine.

MA112180_33 6/27/2005

Installation

CAUTION! Equipment Damage. Follow all locally approved procedures and safety

practices when lifting and installing this machine. Improper lifting can result in machine

damage.

Select a location for your IsoMet

1000 Precision Saw that provides an adequate working space

and a power source.

The IsoMet

1000 Precision Saw is 15 ½ inches (394 mm) wide, 21 inches (533 mm) deep, and

12 inches (305 mm) high. Placement of the IsoMet

1000 Precision Saw should be on a sturdy,

level bench. Buehler TECH-MET

tables are highly recommended.

Allow 6 inches (150 mm) of space at the back of the IsoMet

1000 Precision Saw for raising the

hood. Make sure to leave sufficient space on both sides for sectioning long bars.

Electrical Installation

WARNING! Electrical Shock Hazard. Do not change the power plug in any

way. Buehler machines are equipped with a polarized plug (one blade is wider

than the other) and a ground pin. Polarized plugs reduce the risk of electrical

shock. This plug will fit in a polarized outlet only one way.

Check that Specification Plate values for voltage, current, and power consumption are

compatible with the intended electrical supply before installation.

The IsoMet

1000 Precision Saw can be plugged into an outlet rated for the voltage and

frequency listed on the Specification Plate.

WARNING! Electrical Shock Hazard. A qualified electrical technician should

perform electrical maintenance.

• Disconnect the power supply before making any electrical adjustments.

• Capacitors inside the machine may retain a charge even if the machine

is disconnected from the power supply.

• Installation of the IsoMet

1000 Precision Saw must comply with local

electrical standards or codes of practice.

IsoMet

1000 Precision Saw Voltage / Frequency

11-2180 85 – 264 Volts / 50 – 60 Hz

Table 1 IsoMet

1000 Electrical Data

MA112180_33 6/27/2005

Activating the IsoMet

1000 Precision Saw

To activate power to the IsoMet

1000 Precision Saw flip the power switch on the back of

the machine to the UP position.

The IsoMet

1000 power switch is also a two-pole circuit breaker that will provide

protection for the machine in the event of an overload.

If at any time the Front Control Panel buttons or the motor does not operate, reset the

IsoMet

1000 by flipping the power switch to the DOWN position then back to the UP

position.

Blade Installation

1. Remove the thumbscrew, end cap bushing, and outer flange from the arbor shaft

(see Figure 2).

2. Install the blade on the arbor shaft against the inner flange.

3. Slide the outer flange, the end cap bushing, and the thumbscrew on to the arbor

shaft.

4. Hand tightened the thumbscrew to secure the blade.

Inner Flan

Blade

rbor Shaft

Outer Flan

End Cap Bushin

Thumbscrew

Figure 2 Blade Installation

MA112180_33 6/27/2005

Gang Sawing

Several blades can be installed to the IsoMet

1000 for gang sawing.

1. Install the blades with the appropriate spacers.

2. Slide the outer flange, the end cap bushing, and the thumbscrew on to the arbor

shaft.

3. Hand tightened the thumbscrew to secure the blades.

Flanges

CAUTION! Equipment Damage. Flanges provide support for wafering blades.

Failure to provide adequate flange support can result in curved cuts and

damaged blades.

Always select the maximum flange diameter to correspond with the sample size.

Before re-installing a wafering blade, clean the flanges, end cap bushing, and

thumbscrew. This will help prevent misalignment of the blade and prevent poor quality

cuts.

Blade Dressing

New wafering blades (including the original equipment blade) must be dressed before

making any cuts.

Blade dressing removes built up matrix metal and exposes the abrasive grain to provide

clean, aggressive cutting. New wafering blades should be dressed several times and

older blades should be dressed as required.

Note: When cutting metal, it may be necessary to dress the blade after each cut.

To dress a wafering blade:

1. Position the dressing stick in the dressing chuck.

• From the front of the machine, pull the lubricant tank straight out until the blade

makes contact with the back of the tank. The dressing chuck will now be

exposed.

• Position the dressing stick as needed.

• Close the lubricant tank.

2. Close the hood.

3. Press the SAW button to activate the saw.

4. Rotate the Dressing Stick Feed Control knob clockwise to feed the dressing stick into

the wafering blade (see Figure 3).

MA112180_33 6/27/2005

5. Make as many cross cuts through the dressing stick as needed to dress the blade.

Three to five crosscuts usually work well.

Lubricant Tank

Dressing Chuck with a Dressing Stick

Dressing Stick Feed Control Knob

Figure 3 Dressing Chuck inside the Lubricant Tank

WARNING! Personal Injury. Feeding the dressing stick or any specimen

sample into the blade by hand can result in severe personal injury and equipment

damage.

Lubrication

The IsoMet

1000 Precision Saw uses the drag principle of lubrication. The lubricant is

carried to the sample on the edge of the rotating blade.

IsoCut

Plus Fluid reduces cutting time and produces superior cuts. IsoCut

Plus Fluid

is best for most metals and many non-metals. The use of IsoCut

Plus Fluid promotes

effective lubrication enables diamond particles to cut cleanly and minimizes loading of the

blade.

• Fill the IsoMet

1000 lubricant tank with IsoCut

Plus Fluid to a level that will

immerse the blade approximately ¼-inch.

• Discard the lubricant when becomes contaminated with sludge.

a. Remove the sample tray, wafering blade, and flanges from the arbor shaft.

b. From the front of the machine, pull the lubricant tank straight out.

c. Discard the lubricant in a safe and approved manner.

d. Clean the lubricant tank.

e. Reinstall the lubricant tank.

f. Refill the lubricant tank with fresh, clean lubricant.

g. Reinstall the wafering blade, flanges, and sample tray.

MA112180_33 6/27/2005

Operation

Sample Arm

Dressing Stick Feed Arm

End of Cut Adjustment Knob

Counterbalance Weight

Load Weight

Sample Positioning Knob

Lubricant Tank

Figure 4 IsoMet

1000 Precision Saw Components

MA112180_33 6/27/2005

IsoMet

1000 Front Control Panel

ZERO

INCH

CHUCK BLADE

POWER

POSITION

SPEED

IsoMet 1000

PRECISION SAW

BUEHLER

Figure 5 IsoMet

1000 Front Control Panel

ZERO

POSITION (ZERO) Resets the blade position to zero. The POSITION LCD will

display 00.0.

INCH

UNITS (MM / INCH) Displays either millimeters or inches as the unit of

measurement in the POSITION LCD.

The default unit of measurement is inches. The indicator light

will light up for the unit of measure selected.

POSITION FIELD Displays the distance of the blade from the set ZERO position.

INCREASE Increases the blade speed in increments of 25 rpms. Press and

hold the INCREASE button for rapid speed selection.

DECREASE Decreases the blade speed in increments of 25 rpms. Press and

hold the DECREASE button for rapid speed selection.

SPEED FIELD Displays the blade speed in rpms. The minimum blade speed is

100 rpms. The maximum blade speed is 950 rpms.

Note: The IsoMet

1000 will retain to the last selected speed.

CHUCK

CHUCK Only used with the Rotating Chuck accessory. Activates and

deactivates the Rotating Chuck. The indicator light will light up

when the chuck is activated.

MA112180_33 6/27/2005

BLADE

BLADE Activates and deactivates the blade. The indicator light will light

up when the blade is running.

POWER Activates and deactivates power to the IsoMet

1000.

Sample Arm

The Sample Arm has three positions to select from (see Figure 6). The position selected

depends on the diameter of the wafering blade (4-inch to 7-inch) and the angle of

engagement between the blade and the sample.

7-in

h Di

r Bl

ade

-in

h Di

r Bl

ade

5-inch Diameter Blade

inch Diameter Blade

-in

h Fl

Chuck

Sample Arm

Sample Arm Positioning

Figure 6 Sample Arm Positioning

MA112180_33 6/27/2005

Loading the Saw

Counter-balance Weight

Weight Arm

Weight Arm on the ISOMET

1000

Sample Positioning

Knob

Load Weight

Figure 7 Weight Arm

1. On the left side of the IsoMet

1000 is the Weight Arm. Lift the Weight Arm to the

locked position.

2. Loosen the thumbscrew on the Load Weight.

3. Slide the weight to the zero setting.

4. Select the proper chuck for the application and clamp the sample in the chuck.

• To clamp odd or irregular samples, it may be necessary to sandwich metal strips

between the sample and the chuck.

5. Attach the sample loaded chuck to the Sample Arm with the supplied screw (a socket

head cap).

6. Once the chuck is secure, rotate the Sample Positioning knob to move the Sample

Arm to the far left.

7. Lower the Weight Arm so it lays horizontal.

8. Slide the counter-balance weight up or down until a balance is achieved.

9. Tighten the thumbscrew on the counter-balance weight to secure the weight.

• If a large chuck or a heavy sample is used, a balance may not be achieved.

• If the sample is load sensitive, deduct the unbalanced weight from the Load

Weight setting.

10. Set the Load Weight to the desired load as marked on the Weight Arm.

• The Weight Arm is calibrated from zero (0) to 500 grams. 300 grams of

additional weight can be added with the optional weight kit.

• Lighter weights are recommended since heavier loads can cause greater surface

damage to the sample.

MA112180_33 6/27/2005

End of Cut Adjustment

The End of Cut Adjustment knob is located under the hood on the IsoMet

1000 housing

(see Figure 8).

The End of Cut Adjustment knob sets the total travel of the Sample Arm and stops the

blade when the travel is complete. This End of Cut feature can also be used to cut a

sample to a certain depth.

The arm travel can be set to stop the saw either just before a cut is complete or when a

cut is complete. By setting the End of Cut feature to deactivate the saw just before a cut

is complete reduces the weight on the sample and prevents the possible burring or

cleavage of fragile materials near the end of a cut.

An alternative for minimizing burring and to prevent cleavage of fragile materials is to use

a double saddle chuck.

Note: The End of Cut feature must be positioned and set to prevent the sample and/or

chuck from riding on the blade flanges after the cut is complete.

End of Cut Adjustment Knob

Figure 8 IsoMet

1000

Cutting a Sample

1. Using the appropriate chuck, load the sample and chuck on to the Sample Arm.

Note: Do not scratch the blade or drop a sample on the wafering blade’s edge.

2. Raise the Sample Arm to adjust the position of the sample.

3. Rotate the Sample Positioning knob to move the sample left or right.

• The Front Control Panel will display the numerical movement of the sample.

4. Lower and hold the Sample Arm with the sample just above the wafering blade.

5. Rotate the Sample Positioning knob until the sample touches the side of the wafering

blade.

6. Press the DISPLAY (ZERO) button to reset the POSITION LCD to zero (00.0).

MA112180_33 6/27/2005

7. Raise the Sample Arm to the locked position.

8. Press the UNITS button to display millimeters or inches.

9. Advance the sample as required.

10. Close the hood.

11. Press the SAW (RUN/STOP) button to activate the blade.

12. Press the INCREASE or DECREASE buttons to set the blade speed.

Note: Faster speeds (and heavier weights) tend to damage the sample surface.

13. The cut cycle will begin.

14. If the End of Cut Adjustment has been set, the blade will automatically stop when the

cut is complete.

MA112180_33 6/27/2005

Maintenance

The IsoMet

1000 Precision Saw will continue to perform at optimum levels with proper care,

daily cleaning, and general maintenance.

The protective hood and touch-panel control pad should be cleaned using mild soap and water

applied with a soft cloth. Do not use ammonia-based cleaners, i.e. Windex

. Cloudiness and

cracking can occur.

Exterior painted surfaces, including the cutting chamber, should be cleaned with a non-abrasive

household cleaner.

Note: When the IsoMet

™

is used in a Hot Cell or Glove Box, the inert atmosphere may cause

excessive motor brush wear. Brushes may need to be replaced monthly. This

replacement is not covered under the warranty

Trouble Shooting Chart

Problem Possible Cause Correction

Check the power cord

connection.

The unit is not plugged in.

The IsoMet

does not

power on.

The unit is not powered on.

Check the rear power

switch.

Wrong blade for the

material.

Replace with correct blade.

Improper sample fixture

(primary cause).

Use correct sample fixture.

The blade keeps pinching.

Blade may need to be

dressed.

Dress blade.

Check the coolant for

proper mixture.

Improper coolant mixture.

The bed has rust on it.

The hood has been closed

too long with moisture build

up.

Open hood and keep hood

open when not in use.

Check the cable

connection.

Cable is disconnected.

The Rotating Chuck does

not work.

Rotating chuck is not

powered on.

Make certain the Rotating

Chuck is turned on.

Make certain the table is

level.

Table or unit is not level.

Coolant leaks from the

IsoMet

Coolant level too high.

Check the volume of

cutting fluid.

MA112180_33 6/27/2005

IsoMet

1000 Precision Saw Accessories

IsoMet

1000 Accessories

Catalog No. Description

Chucks

11-1183 Chuck ....................................... Double Saddle Type

11-1184 Chuck ....................................... For Bar and Tube Stock

11-1185 Chuck ....................................... For Irregular Shaped Specimens

11-1186 Chuck ....................................... For Wafers Single Crystals and Thin Sections

11-1187 Chuck ....................................... For Long Samples, Single Saddle Type

11-1188 Chuck ....................................... For Petrographic and Ceramographic Thin Sections

11-1189 Chuck ....................................... For 1-inch or 1 ½-inch Diameter Specimens (Requires

the use of 11-1192 Recessed Flanges)

11-2482 Fastener Chuck ........................ For Longitudinal Sectioning of Fasteners, Tubes, and

Solid Cylinders

11-2489 Specimen Chuck ...................... For 1 ½-inch and 40 mm Mounted Samples

11-2483 Double Saddle Chuck............... 1-inch Diameter Capacity

11-2484 Glass Slide Chuck .................... 27 mm x 46 mm Glass Slide for Thin Sections

11-2488 Glass Slide Chuck.................... 2-inch x 3-inch Glass Slide for Thin Sections

11-2496 Chuck Padding ......................... Applied to Chucks for Holding Brittle or Friable

Specimens

Flanges

11-1191 Flange....................................... 1 ½-inch Diameter, Recessed

11-1192 Flange....................................... 1 ⅜-inch Diameter, Recessed

(For use with 11-1188 Chuck and 11-1189 Chuck)

11-2282 Flange....................................... 3-inch Diameter

11-2283 Flange....................................... 4-inch Diameter

11-2284 Flange....................................... 5-inch Diameter

Other

11-1190 Dressing Stick .......................... For Dressing Series 15 and 20 Wafering Blades

11-1290 Dressing Stick .......................... For Dressing Series 5 and 10 Wafering Blades

11-2181 Rotating Chuck Accessory ....... For Holding and Rotating Samples up to

2-inch in Diameter

11-2182 Table Saw Attachment ............. For Hand-Cutting Long or Irregular Specimens

11-2186 Splash Shield ........................... For use with the 11-2182 Table Saw Attachment

11-2183 Accessory Weight Set .............. For Increasing Cutting Load to 800 gm

11-2185 IsoMet

1000 Goniometer ........ For Sectioning Crystals

11-2293-016 IsoCut

Cutting Fluid ........ 1 Pint (.48 liter)

MA112180_33 6/27/2005

IsoMet

1000 Precision Saw Accessories

Wafering Blades

Blade Series Diameter and Thickness

3" x 0.006"

(75 x 0.2 mm)

4" x 0.012"

(100 x 0.3 mm)

5" x 0.015"

(125 x 0.4 mm)

6" x 0.020"

(150 x 0.5mm)

7" x 0.025"

(180 x 0.6mm)

30 HC

11-4239** 11-4241**

For use with plastics, polymers, and rubber

20 HC

11-4215* 11-4237

For aggressive general sectioning of ferrous and non-ferrous materials

15 HC

11-4243 11-4244 11-4245 11-4246 11-4247

For routine use, metal matrix composites, PC boards, and thermal spray coatings

20 LC

11-4225* 11-4227

For use with hard/tough materials, structural ceramics, boron carbide, boron nitride, silicon nitride

15 LC

11-4253 11-4254 11-4255 11-4276 11-4277

For use with hard/brittle materials, structural ceramics, electronic substrates, alumina, zirconia,

silicon carbide

10 LC

11-4283 11-4285 11-4287

For use with medium to soft ceramics, electronic packages, GaAs, AIN, and glass fiber reinforced

composites

5 LC

11-4289 11-4295

For use with soft friable ceramics, composites with fine reinforcing media, CaF

, MgF

, and

carbon composites

ISOCUT

11-4263 11-4264 11-4265 11-4266 11-4267

Wafering Blades: For iron and cobalt based alloys, nickel base super alloys, and lead base alloys

**Alternate Blade Thickness of 0.020" (0.5 mm)

*Alternate Blade Thickness of 0.030" (0.8 mm)

MA112180_33 6/27/2005

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Buehler 11-2180 User manual

Brand: Buehler

Model: 11-2180

Type: User manual

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